Header panel assembly for preventing air circulation above electronic equipment enclosure

ABSTRACT

A hot/cold aisle containment system includes a frame structure, at least one electronic equipment enclosure installed at least partially within the frame structure, and a header panel assembly. The frame structure is adapted to be at least partially covered by one or more panels to define an interior space and includes a vertical member and a horizontal member. The header panel assembly is installed between a top of the at least one electronic equipment enclosure and the horizontal member of the frame structure to prevent circulation of air above the enclosure. The header panel assembly includes a main panel and at least one seal.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a U.S. non-provisional patent application of,and claims priority under 35 U.S.C. §119(e) to, each of U.S. provisionalpatent application Ser. No. 61/411,359, filed Nov. 8, 2010, and U.S.provisional patent application Ser. No. 61/411,373, filed Nov. 8, 2010,each of which is expressly incorporated by reference herein in itsentirety.

COPYRIGHT STATEMENT

All of the material in this patent document is subject to copyrightprotection under the copyright laws of the United States and othercountries. The copyright owner has no objection to the facsimilereproduction by anyone of the patent document or the patent disclosure,as it appears in official governmental records but, otherwise, all othercopyright rights whatsoever are reserved.

BACKGROUND OF THE PRESENT INVENTION

1. Field of the Present Invention

The present invention relates generally to structures and methods ofthermal management in a data center, and, in particular, to a headerpanel assembly for installation above electronic equipment enclosures ina hot aisle containment structure.

2. Background

Rack-mounted computer and data storage equipment generates heat duringnormal operation. When equipment is enclosed in racks, cabinets andother electronic equipment enclosures (hereinafter, collectively,referred to as “enclosures”), heat generated by the equipment canconcentrate within the enclosure and cause equipment to overheat andshut down. Thus, proper thermal management is a fundamental aspect ofthe installation and use of such equipment. Moreover, thermal managementis particularly important in data centers in which multiple enclosuresare installed, each with heat-generating equipment mounted therein.

Many techniques and solutions have been proposed and used with regard tothermal management in such data centers. One such solution involvesutilization of a containment structure to receive heated exhaust airfrom enclosures installed in the data center or computer room.Enclosures are typically arranged in a row facing with their sidesabutting one another. Cool air is drawn into the enclosures from outsidethe containment structure to cool the equipment mounted in eachenclosure. Heated exhaust air is then expelled from the enclosures intoa common area within the containment structure, which is segregated fromthe supply of cool air. Heated exhaust air may then be routed from thecontainment structure and cooled before being re-circulated into thesupply of cool air.

A common difficulty encountered in many known containment structuresinvolves co-mingling of the heated exhaust air with the supply of coolair, which negatively impacts efficiency in the system. Co-mingling mayoccur for a variety of reasons, but often arises in connection withopenings or gaps surrounding enclosures that are installed in thestructure. If a gap exists after an enclosure is installed in thestructure, heated exhaust air has the potential to travel through thegap and back into the supply of cool air, thereby reducing coolingefficiency in the system. For example, the gaps that have long existedbetween the tops of enclosures and the ceiling or other structure abovethe enclosures permit recirculation of heated air that has beenexhausted from the rear of an enclosure over the enclosure where itmingles with the cooling air being supplied to the front of theenclosure for intake therein.

Additionally, openings or gaps in the containment structure may have theeffect of causing equipment located near the gap to run at a higheroperating temperature as warmer air that escapes from within thecontainment structure is drawn back in to cool the equipment. As aresult, over time, such equipment may have a decreased operating liferelative to other equipment installed therein.

Further issues may arise if enclosures with varying dimensions areinstalled within the same containment structure. For example, ifenclosures with different vertical dimensions happen to be installedadjacent to one another within the same containment structure,differently-sized panels or blanks must be used to seal off any gapsthat are formed above the enclosures. If such panels do not provide agood fit to seal the gap, then inefficiency is likely to exist as heatedexhaust air escapes from the containment structure and mixes with thesupply of cool air.

Accordingly, a need exists for a containment system that avoids theshortcomings of known containment structure solutions. This, and otherneeds, are addressed by one or more aspects of the present invention.

SUMMARY OF THE PRESENT INVENTION

Broadly defined, the present invention according to a first aspectincludes a hot/cold aisle containment system substantially as shown anddescribed.

Broadly defined, the present invention according to a second aspectincludes a hot/cold aisle containment system having a header panelassembly installed between a horizontal member thereof and an electronicequipment enclosure, substantially as shown and described.

Broadly defined, the present invention according to a third aspectincludes a hot/cold aisle containment system. The containment systemincludes a frame structure, at least one electronic equipment enclosureinstalled at an end of the frame structure, and a header panel assembly.The frame structure is adapted to be at least partially covered by oneor more panels to define an interior space and includes a verticalmember and a horizontal member. The header panel assembly is installedbetween a top of the at least one electronic equipment enclosure and thehorizontal member of the frame structure to prevent circulation of airabove the enclosure.

In features of this aspect, the header panel assembly may include a mainpanel and at least one seal, the at least one seal being disposed alongthe lower edge of the main panel and adapted to be held in place betweenthe bottom of the main panel and a top surface of the at least oneelectronic equipment enclosure; the at least one seal may becompressible; the header panel assembly may further include a fixedbracket adapted to be supported by the horizontal member of the framestructure, wherein the main panel is adapted to be adjustably coupled tothe fixed bracket; the header panel assembly may further include atleast one clamp for retaining a portion of the main panel against aportion of the fixed bracket; a V-shaped flange may be disposed at thelower edge of the main panel, wherein the at least one seal is disposedat least partially in a groove defined by the V-shaped flange; and aV-shaped flange may be disposed at a side edge of the main panel,wherein the at least one seal is disposed at least partially in a groovedefined by the V-shaped flange.

In further features of this aspect, the hot/cold aisle containmentsystem may further include a side seal assembly installed between a sideof the at least one electronic equipment enclosure and the verticalmember of the frame structure to prevent circulation of air around theenclosure; the side seal assembly may include a vertical support bracketand at least one seal, the vertical support bracket being adapted tosupport the side seal assembly from the vertical member of the framestructure; the vertical support bracket may include one or morehorizontal slots to facilitate lateral adjustment thereof; a V-shapedflange may be disposed along an edge of the vertical support bracket,wherein the at least one seal is disposed at least partially in a groovedefined by the V-shaped flange; and the side seal assembly may beadapted to extend from the top to the bottom of the frame structure.

Broadly defined, the present invention according to a fourth aspectincludes a hot/cold aisle containment system. The containment systemincludes a frame structure, at least one electronic equipment enclosureinstalled at an end of the frame structure, and a side seal assembly.The frame structure is adapted to be at least partially covered by oneor more panels to define an interior space and includes a verticalmember. The side seal assembly is installed between a side of the atleast one electronic equipment enclosure and the vertical member of theframe structure to prevent circulation of air around the enclosure.

In features of this aspect, the side seal assembly may include avertical support bracket and at least one seal, the vertical supportbracket being adapted to support the side seal assembly from thevertical member of the frame structure; the vertical support bracket mayinclude one or more horizontal slots to facilitate lateral adjustmentthereof; and a V-shaped flange may be disposed along an edge of thevertical support bracket, wherein the at least one seal is disposed atleast partially in a groove defined by the V-shaped flange.

Broadly defined, the present invention according to a fifth aspectincludes a hot/cold aisle containment system. The containment systemincludes a frame structure, a header panel assembly, a side sealassembly, and at least one electronic equipment enclosure. The framestructure is adapted to be at least partially covered by one or morepanels to define an interior space and includes a vertical member and ahorizontal member. The header panel assembly depends from the horizontalmember of the frame structure, and the side seal assembly depends fromthe vertical member of the frame structure. The at least one electronicequipment enclosure is installed at least partially within the framestructure such that a top of the enclosure is sealed by the header panelassembly and a side of the enclosure is sealed by the side sealassembly.

In features of this aspect, the header panel assembly may include a mainpanel and at least one seal, the at least one seal being disposed alongthe lower edge of the main panel and adapted to be held in place betweenthe bottom of the main panel and a top surface of the at least oneelectronic equipment enclosure; the at least one seal may becompressible; the header panel assembly may further include a fixedbracket adapted to be supported by the horizontal member of the framestructure, wherein the main panel is adapted to be adjustably coupled tothe fixed bracket; the header panel assembly may further include atleast one clamp for retaining a portion of the main panel against aportion of the fixed bracket; a V-shaped flange may be disposed at thelower edge of the main panel, wherein the at least one seal is disposedat least partially in a groove defined by the V-shaped flange; and aV-shaped flange may be disposed at a side edge of the main panel,wherein the at least one seal is disposed at least partially in a groovedefined by the V-shaped flange.

In further features of this aspect, the side seal assembly may include avertical support bracket and at least one seal, the vertical supportbracket being adapted to support the side seal assembly from thevertical member of the frame structure; the vertical support bracket mayinclude one or more horizontal slots to facilitate lateral adjustmentthereof; a V-shaped flange may be disposed along an edge of the verticalsupport bracket, wherein the at least one seal is disposed at leastpartially in a groove defined by the V-shaped flange; and the side sealassembly may be adapted to extend from the top to the bottom of theframe structure.

Broadly defined, the present invention according to a sixth aspectincludes a header panel assembly, for use in connection with a hot/coldaisle containment system, substantially as shown and described.

Broadly defined, the present invention according to a seventh aspectincludes a header panel assembly. The header panel assembly includes afixed bracket, adapted to be supported by a horizontal frame structureof a hot/cold aisle containment system; a main panel, having a loweredge, that is adjustably coupled to the fixed bracket; and a seal,disposed along the lower edge of the main panel, that is adapted to beheld in place between the bottom of the main panel and a top surface ofat least one electronic equipment enclosure installed beneath the headerpanel assembly.

In features of this aspect, the seal may be compressible; the headerpanel assembly may further include at least one clamp for retaining aportion of the main panel against a portion of the fixed bracket; aV-shaped flange may be disposed at the lower edge of the main panel,wherein the seal is disposed at least partially in a groove defined bythe V-shaped flange; and the main panel may further include a side edgehaving an additional V-shaped flange, wherein an additional seal isdisposed along the side edge at least partially in a groove defined bythe additional V-shaped flange and is adapted to be held in placebetween the side of the main panel and an adjacent structure.

Broadly defined, the present invention according to an eighth aspectincludes a header panel assembly. The header panel assembly includes afixed bracket, adapted to be supported by a horizontal frame structureof a hot/cold aisle containment system; a main panel, having a sideedge, that is adjustably coupled to the fixed bracket; and a seal,disposed along the side edge of the main panel, that is adapted to beheld in place between the side of the main panel and an adjacentstructure.

In features of this aspect, the seal may be compressible; a V-shapedflange may be disposed at the side edge of the main panel, wherein theseal is disposed at least partially in a groove defined by the V-shapedflange; and the adjacent structure may be a side seal assembly.

Broadly defined, the present invention according to a ninth aspectincludes a side seal assembly, for use in connection with a hot/coldaisle containment system, substantially as shown and described.

Broadly defined, the present invention according to a tenth aspectincludes a side seal assembly. The side seal assembly includes avertical support bracket, adapted to be supported by a vertical framestructure of a hot/cold aisle containment system, that includes aV-shaped flange extending vertically along the side thereof; and a seal,disposed within a groove defined by the V-shaped flange, that is adaptedto be held in place between the side of the vertical support bracket andan adjacent electronic equipment enclosure.

In features of this aspect, the seal may be compressible; and thevertical support bracket may include one or more horizontal slots tofacilitate lateral adjustment thereof.

Broadly defined, the present invention according to an eleventh aspectincludes a method of sealing a hot/cold aisle containment system assubstantially shown and described.

Broadly defined, the present invention according to a twelfth aspectincludes a hot/cold aisle containment system that includes a framestructure and at least one electronic equipment enclosure installed atleast partially within the frame structure, and a header panel assembly.The frame structure is adapted to be at least partially covered by oneor more panels to define an interior space. The frame structure includesa vertical member and a horizontal member. The header panel assembly isinstalled between a top of the at least one electronic equipmentenclosure and the horizontal member of the frame structure to preventcirculation of air above the enclosure. The header panel assemblyincludes a main panel and at least one seal.

In features of this aspect, the at least one seal may be disposed alongthe lower edge of the main panel and adapted to be held in place betweenthe bottom of the main panel and a top surface of the at least oneelectronic equipment enclosure; the at least one seal may be disposedalong a side edge of the main panel and adapted to be held in placebetween the side of the main panel and an adjacent structure; the headerpanel assembly may further include a fixed bracket adapted to besupported by the horizontal member of the frame structure, and the mainpanel may be adapted to be adjustably coupled to the fixed bracket; andthe header panel assembly may further include at least one clamp forretaining a portion of the main panel against a portion of the fixedbracket.

In further features of this aspect, a V-shaped flange may be disposed atan edge of the main panel, and the at least one seal may be disposed atleast partially in a groove defined by the V-shaped flange; a generallyperpendicular flange may be disposed at an edge of the main panel, andthe at least one seal may be disposed along an outer edge of thegenerally perpendicular flange; and an angled flange may be disposed atan edge of the main panel, and the at least one seal may be disposedalong an outer edge of the angled flange.

In still further features of this aspect, the at least one seal may becompressible; the at least one seal may be a brush seal; and the atleast one seal may be a deflectable blade seal.

In still further features of this aspect, the hot/cold aisle containmentsystem may further include a side seal assembly installed between a sideof the at least one electronic equipment enclosure and the verticalmember of the frame structure to prevent circulation of air around theenclosure; the side seal assembly may include a vertical support bracketand at least one seal, the vertical support bracket being adapted tosupport the side seal assembly from the vertical member of the framestructure; the vertical support bracket may include one or morehorizontal slots to facilitate lateral adjustment thereof; a V-shapedflange may be disposed along an edge of the vertical support bracket,and the at least one seal may be disposed at least partially in a groovedefined by the V-shaped flange; and the side seal assembly may beadapted to extend from the top to the bottom of the frame structure.

In still another feature of this aspect, the main panel may be mountedto the horizontal member and adapted to be adjustable in a verticaldirection relative to the horizontal member.

Broadly defined, the present invention according to a thirteenth aspectincludes a hot/cold aisle containment system that includes a framestructure, at least one electronic equipment enclosure installed atleast partially within the frame structure, and a side seal assembly.The frame structure is adapted to be at least partially covered by oneor more panels to define an interior space, and the frame structureincludes a vertical member. The side seal assembly is installed betweena side of the at least one electronic equipment enclosure and thevertical member of the frame structure to prevent circulation of airaround the enclosure.

In features of this aspect, the side seal assembly may include avertical support bracket and at least one seal, the vertical supportbracket being adapted to support the side seal assembly from thevertical member of the frame structure; the vertical support bracket mayinclude one or more horizontal slots to facilitate lateral adjustmentthereof; and a V-shaped flange may be disposed along an edge of thevertical support bracket, and the at least one seal may be disposed atleast partially in a groove defined by the V-shaped flange.

Broadly defined, the present invention according to a fourteenth aspectincludes a hot/cold aisle containment system that includes a framestructure, a header panel assembly, a side seal assembly, and at leastone electronic equipment enclosure installed at least partially withinthe frame structure. The frame structure is adapted to be at leastpartially covered by one or more panels to define an interior space, andthe frame structure includes a vertical member and a horizontal member.The header panel assembly depends from the horizontal member of theframe structure, and the header panel assembly includes a main panel andat least one seal. The side seal assembly depends from the verticalmember of the frame structure. The at least one electronic equipmentenclosure is installed at least partially within the frame structuresuch that a top of the enclosure is sealed by the header panel assemblyand a side of the enclosure is sealed by the side seal assembly.

In features of this aspect, the at least one seal may be disposed alongthe lower edge of the main panel and adapted to be held in place betweenthe bottom of the main panel and a top surface of the at least oneelectronic equipment enclosure; the at least one seal may be disposedalong a side edge of the main panel and adapted to be held in placebetween the side of the main panel and an adjacent structure; the headerpanel assembly may further include a fixed bracket adapted to besupported by the horizontal member of the frame structure, and the mainpanel may be adapted to be adjustably coupled to the fixed bracket; andthe header panel assembly may further include at least one clamp forretaining a portion of the main panel against a portion of the fixedbracket.

In further features of this aspect, a V-shaped flange may be disposed atan edge of the main panel, and the at least one seal may be disposed atleast partially in a groove defined by the V-shaped flange; a generallyperpendicular flange may be disposed at an edge of the main panel, andthe at least one seal may be disposed along an outer edge of thegenerally perpendicular flange; and an angled flange may be disposed atan edge of the main panel, and the at least one seal may be disposedalong an outer edge of the angled flange.

In further features of this aspect, the at least one seal may becompressible; the at least one seal may be a brush seal; and the atleast one seal may be a deflectable blade seal.

In further features of this aspect, the side seal assembly may include avertical support bracket and at least one seal, the vertical supportbracket being adapted to support the side seal assembly from thevertical member of the frame structure; the vertical support bracket mayinclude one or more horizontal slots to facilitate lateral adjustmentthereof; a V-shaped flange may be disposed along an edge of the verticalsupport bracket, and the at least one seal may be disposed at leastpartially in a groove defined by the V-shaped flange; and the side sealassembly may be adapted to extend from the top to the bottom of theframe structure.

In still another feature of this aspect, the main panel may be mountedto the horizontal member and adapted to be adjustable in a verticaldirection relative to the horizontal member.

Broadly defined, the present invention according to a fifteenth aspectincludes a header panel assembly that includes a fixed bracket, a mainpanel that is adjustably coupled to the fixed bracket, and at least oneseal disposed along an edge of the main panel. The fixed bracket isadapted to be supported by a horizontal frame structure of a hot/coldaisle containment system. The at least one seal is adapted to be held inplace between the main panel and an adjacent structure.

In a feature of this aspect, the header panel assembly may furtherinclude at least one clamp for retaining a portion of the main panelagainst a portion of the fixed bracket.

In further features of this aspect, a V-shaped flange may be disposed atan edge of the main panel, and the at least one seal may be disposed atleast partially in a groove defined by the V-shaped flange; a generallyperpendicular flange may be disposed at an edge of the main panel, andthe at least one seal may be disposed along an outer edge of thegenerally perpendicular flange; and an angled flange may be disposed atan edge of the main panel, and the at least one seal may be disposedalong an outer edge of the angled flange.

In still further features of this aspect, the at least one seal may becompressible; the at least one seal may be a brush seal; and the atleast one seal may be a deflectable blade seal.

In still further features of this aspect, the at least one seal may bedisposed along a lower edge of the main panel; and the at least one sealmay be disposed along a side edge of the main panel.

In still further feature of this aspect, the adjacent structure may bean electronic equipment enclosure; and the adjacent structure may be aside seal assembly.

Broadly defined, the present invention according to a sixteenth aspectincludes a side seal assembly, that includes a vertical support bracketand a seal. The vertical support bracket is adapted to be supported by avertical frame structure of a hot/cold aisle containment system andincludes a V-shaped flange extending vertically along the side thereof.The seal is disposed within a groove defined by the V-shaped flange andis adapted to be held in place between the side of the vertical supportbracket and an adjacent electronic equipment enclosure.

In features of this aspect, the seal may be compressible; the seal maybe a brush seal; and the seal may be a deflectable blade seal.

In another feature of this aspect, the vertical support bracket mayinclude one or more horizontal slots to facilitate lateral adjustmentthereof.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features, embodiments, and advantages of the present inventionwill become apparent from the following detailed description withreference to the drawings, wherein:

FIG. 1 is an isometric view of a hot/cold aisle containment system inuse with a row of electronic equipment enclosures in accordance with apreferred embodiment of the present invention;

FIG. 2 is an isometric view of the frame structure of FIG. 1;

FIG. 3 is an isometric view of one of the header panel assemblies ofFIG. 1;

FIG. 4 is a reverse isometric view of the header panel assembly of FIG.3;

FIG. 5 is an orthogonal exploded view of the header panel assembly ofFIG. 3;

FIG. 6 is a rear plan view of the main header panel of FIG. 3;

FIG. 7 is an end cross-sectional view of the main panel of FIG. 6, takenalong line 7-7;

FIG. 8 is a bottom view of the main panel of FIG. 6;

FIG. 9 is a schematic view of a seal mounted in one of the V-shapedgrooves of the main header panel of FIG. 6;

FIG. 10 is a fragmentary top cross-sectional view of the left edge ofthe header panel assembly of FIG. 3, taken along line 10-10;

FIGS. 11-13 are fragmentary top cross-sectional views, similar to thatof FIG. 10, of the left edge of various alternative header panelassembly embodiments;

FIGS. 14A-14C are isometric views of header panel assemblies similar tothat of FIG. 3 but having different vertical dimensions;

FIG. 15 is an isometric view of one of the side seal assemblies of FIG.1;

FIG. 16 is a fragmentary top cross-sectional view of the left end of thehot/cold aisle containment system of FIG. 1, taken along line 16-16,illustrating the interface between a header panel assembly and a sideseal assembly;

FIG. 17 is an isometric view of a hot/cold aisle containment system inuse with a row of electronic equipment enclosures in accordance withanother preferred embodiment of the present invention;

FIG. 18 is an isometric view of a hot/cold aisle containment system inuse with an electronic equipment enclosure installed at one side thereofand an adjustable wall assembly temporarily positioned away from theenclosure in accordance with still another preferred embodiment of thepresent invention;

FIG. 19 is an isometric view of an overhanging beam for use in ahot/cold aisle containment system, shown with a pair of adjustableheader panels attached thereto; and

FIG. 20 is a fragmentary top view of adjacent edges of the pair ofadjustable header panels of FIG. 19.

DETAILED DESCRIPTION

As a preliminary matter, it will readily be understood by one havingordinary skill in the relevant art (“Ordinary Artisan”) that the presentinvention has broad utility and application. Furthermore, any embodimentdiscussed and identified as being “preferred” is considered to be partof a best mode contemplated for carrying out the present invention.Other embodiments also may be discussed for additional illustrativepurposes in providing a full and enabling disclosure of the presentinvention. As should be understood, any embodiment may incorporate onlyone or a plurality of the above-disclosed aspects of the invention andmay further incorporate only one or a plurality of the above-disclosedfeatures. Moreover, many embodiments, such as adaptations, variations,modifications, and equivalent arrangements, will be implicitly disclosedby the embodiments described herein and fall within the scope of thepresent invention.

Accordingly, while the present invention is described herein in detailin relation to one or more embodiments, it is to be understood that thisdisclosure is illustrative and exemplary of the present invention, andis made merely for the purposes of providing a full and enablingdisclosure of the present invention. The detailed disclosure herein ofone or more embodiments is not intended, nor is to be construed, tolimit the scope of patent protection afforded the present invention,which scope is to be defined by the claims and the equivalents thereof.It is not intended that the scope of patent protection afforded thepresent invention be defined by reading into any claim a limitationfound herein that does not explicitly appear in the claim itself.

Thus, for example, any sequence(s) and/or temporal order of steps ofvarious processes or methods that are described herein are illustrativeand not restrictive. Accordingly, it should be understood that, althoughsteps of various processes or methods may be shown and described asbeing in a sequence or temporal order, the steps of any such processesor methods are not limited to being carried out in any particularsequence or order, absent an indication otherwise. Indeed, the steps insuch processes or methods generally may be carried out in variousdifferent sequences and orders while still falling within the scope ofthe present invention. Accordingly, it is intended that the scope ofpatent protection afforded the present invention is to be defined by theappended claims rather than the description set forth herein.

Additionally, it is important to note that each term used herein refersto that which the Ordinary Artisan would understand such term to meanbased on the contextual use of such term herein. To the extent that themeaning of a term used herein—as understood by the Ordinary Artisanbased on the contextual use of such term—differs in any way from anyparticular dictionary definition of such term, it is intended that themeaning of the term as understood by the Ordinary Artisan shouldprevail.

Regarding applicability of 35 U.S.C. §112, ¶6, no claim element isintended to be read in accordance with this statutory provision unlessthe explicit phrase “means for” or “step for” is actually used in suchclaim element, whereupon this statutory provision is intended to applyin the interpretation of such claim element.

Furthermore, it is important to note that, as used herein, “a” and “an”each generally denotes “at least one,” but does not exclude a pluralityunless the contextual use dictates otherwise. Thus, reference to “apicnic basket having an apple” describes “a picnic basket having atleast one apple” as well as “a picnic basket having apples.” Incontrast, reference to “a picnic basket having a single apple” describes“a picnic basket having only one apple.”

When used herein to join a list of items, “or” denotes “at least one ofthe items,” but does not exclude a plurality of items of the list. Thus,reference to “a picnic basket having cheese or crackers” describes “apicnic basket having cheese without crackers,” “a picnic basket havingcrackers without cheese,” and “a picnic basket having both cheese andcrackers.” Finally, when used herein to join a list of items, “and”denotes “all of the items of the list.” Thus, reference to “a picnicbasket having cheese and crackers” describes “a picnic basket havingcheese, wherein the picnic basket further has crackers,” as well asdescribes “a picnic basket having crackers, wherein the picnic basketfurther has cheese.”

Referring now to the drawings, in which like numerals represent likecomponents throughout the several views, the preferred embodiments ofthe present invention are next described. The following description ofone or more preferred embodiment(s) is merely exemplary in nature and isin no way intended to limit the invention, its application, or uses.

FIG. 1 is an isometric view of a hot/cold aisle containment system 10 inuse with a row of electronic equipment enclosures 14 in accordance witha preferred embodiment of the present invention. As shown therein, thecontainment system 10 includes a frame structure 12, a plurality ofheader panel assemblies 50 and a pair of side seal assemblies 100. Eachof these will be discussed in greater detail hereinbelow. Enclosuressuitable for use with preferred embodiments of the present invention aredescribed and illustrated in commonly-assigned U.S. Pat. No. 5,997,117;U.S. Pat. No. 6,185,098; U.S. Pat. No. 7,697,285; U.S. Pat. No.7,804,685; U.S. Patent Application Publication No. US 2009/0227197 A1;and U.S. Patent Application Publication No. US 2010/0172092 A1, theentirety of each of which is incorporated herein by reference.

FIG. 2 is an isometric view of the frame structure 12 of FIG. 1. Asshown therein, the frame structure 12 includes a pair of vertical posts16 and a horizontal beam 17.

FIG. 3 is an isometric view of one of the header panel assemblies 50 ofFIG. 1; FIG. 4 is a reverse isometric view of the header panel assembly50 of FIG. 3; and FIG. 5 is an orthogonal exploded view of the headerpanel assembly 50 of FIG. 3. As shown therein, each header panelassembly 50 includes a main panel 52, a fixed bracket 80, a pair ofclamps 90, and a plurality of seals 55,155. As perhaps best shown inFIGS. 4 and 5, the fixed bracket 80 includes a top mounting flange 82, abottom mounting flange 83 and two side retention flanges 84, allextending from a main body 86. The top and bottom mounting flanges 82,83facilitate attachment to the horizontal beam 17 of the frame structure12. Lateral adjustment along the horizontal beam may be facilitated byslots 85 in the mounting flanges 82,83. The side retention flanges 84are adapted to receive the main panel 52 as more fully describedhereinbelow.

FIG. 6 is a rear plan view of the main header panel 52 of FIG. 3, whileFIG. 7 is an end cross-sectional view of the main panel 52 of FIG. 6,taken along line 7-7, and FIG. 8 is a bottom view of the main panel 52of FIG. 6. As shown therein, the main panel 52 includes V-shaped flanges54,154 along the sides and bottom thereof. Each V-shaped flange 54,154defines a groove 56,156 of corresponding shape. These grooves 56,156 areadapted to receive and retain a respective seal 55,155. In this regard,FIG. 9 is a schematic view of a seal 55 mounted in one of the V-shapedgrooves 56 of the main header panel 52 of FIG. 6. It will be appreciatedthat the seals 55,155 may have any of a wide range of different shapesand configurations and may be comprised of any of a wide range ofdifferent materials. In contemplated embodiments, the seal may be agasket, a brush, a wiper blade, or a compressible bumper. As seen incross-section, each seal 55,155 includes a mounting portion 57 and abody portion 58, wherein the mounting portion 57 is adapted to attach tothe edge of the V-shaped flanges 54,154. Bosses 59 may be provided toassist in such attachment. The body portion 58 is large enough to extendwell outside of the V-shaped groove 56,156 and is comprised of acompressible material of any type conventionally utilized for gaskets,seals, brushes or the like.

When the main panel 52 is positioned within the side retention flanges84 of the fixed bracket 80, the side seals 55 are partially trappedwithin the side V-shaped flanges 54 by the retention flanges 84. This isillustrated in FIG. 10, which is a fragmentary top cross-sectional viewof the left edge of the header panel assembly 50 of FIG. 3, taken alongline 10-10. As shown therein, the upper end 98 of the seal 55 iscompressed into the V-shaped groove 56 by the retention flange 84, whilethe lower end 99 of the seal 55 remains uncompressed. It will beappreciated, however, that when the header panel assembly 50 is properlyinstalled in place next to another header panel assembly 50, a side sealassembly or another structure, the lower end 99 of the seal 55 willusually be compressed as well, thereby sealing the header panel assembly50 against the respective structure.

Referring again to FIG. 6, it will be appreciated that the lower ends ofthe side flanges 54 extend below the bottom of the main panel 52, andthus below the bottom flange 154. This arrangement permits the bottomseal 155 to be placed within the bottom groove 156 such that it may begenerally aligned with the lower end of the side flanges 54, therebyhelping to ensure a complete seal across the bottom of the assembly 50.This is at least partially illustrated in FIG. 3.

With reference to FIGS. 3, 5 and 10, it will be appreciated that thebody of the main panel 52 is penetrated by two clamp apertures 92adapted to receive the clamps 90. In at least some embodiments, theclamps 90 each include a handle 94 and a threaded shaft 96, and athreaded nut 97 is attached behind and around each aperture 92. In otherembodiments, the apertures 92 may themselves be threaded, or maycomprise sheet metal or the like into which threads may be created byscrewing the threaded clamp shaft 96 therethrough. As will beappreciated, the main header panel 52 may be held in place against thefixed bracket 80 by screwing the clamp shafts 96 through the apertures92 in the panel 52 until the ends of the shafts 96 are forced againstthe main body 86 of the fixed bracket 80. In order to preservestructural integrity of the main body 86 of the fixed bracket 80, theend of the shafts 96 may be fitted with protective end caps 87. Whileclamps 90 are shown in the drawings, it is contemplated that a widerange of mechanisms may be used to hold the main panel 52 in placeagainst the fixed bracket 80. In particular, it is contemplated that camlocks, spring fasteners or any of a range of other mechanisms may beimplemented to accomplish the clamping function.

Use of the header panel assembly 50 may perhaps be best understood withreference to FIGS. 1 and 10. Each header panel assembly 50 may beinstalled directly above a respective electronic equipment enclosure 14to fill the space between the top of the enclosure 14 and the framestructure 12 or other structure above it. The vertical length of eachheader panel assembly 50 may be adjusted by loosening the clamps 90 andsliding the main header panel 52 up or down relative to the fixedbracket 80 before retightening the clamps 90. The clamp arrangementpermits the infinite adjustment of the vertical position of the mainheader panel 52 relative to its fixed bracket 80 (within a rangedetermined by the dimensions of the panel 52 and bracket 80), and thusallows the header panel assembly 50 to be custom adjusted to fit thespace between the top of the respective enclosure 14 and the framestructure 12. When installed above the enclosure 14, the header panelassembly 50 thus blocks the space above the enclosure 14 and preventsrecirculation of heated air from the rear of the enclosure 14 over thetop thereof where it could mingle with the cooling air being provided tothe enclosure front.

The infinite adjustability (within the dimensional range) ensures thatair gaps may be substantially entirely eliminated, and differences inenclosure heights managed effectively. This is illustrated, for example,in FIG. 1, where three enclosures 14 have the same approximate height,while a fourth (the second from the right), is shorter than the otherthree. The header panel assemblies 50 for the first three are alladjusted to be the same length, while the header panel assembly 50 forthe fourth enclosure 14 is lengthened to ensure that the bottom of themain panel 52 extends to the top of the enclosure 14 with the bottomseal 155 being compressed between the bottom V-shaped flange 154 and thetop of the enclosure 14.

FIGS. 11-13 are fragmentary top cross-sectional views, similar to thatof FIG. 10, of the left edge of various alternative embodiments ofheader panel assemblies. As shown in FIGS. 11-13, flanges on the mainpanel may have any of a variety of different shapes and configurations.For instance, in FIG. 11, rather than V-shaped flanges, a main panel 41of a header panel assembly 150 includes generally perpendicular flanges43,143 along the sides and bottom thereof Each perpendicular flange43,143 defines an outer edge to accommodate and retain a respective seal55,155. As in the embodiment depicted in FIG. 10, each seal 55,155includes a mounting portion 57 adapted to attach to the edge of theperpendicular flange 43,143. Bosses 59 may be provided to assist in suchattachment. Each seal 55,155 further includes a body portion 58comprised of a compressible material of any type conventionally utilizedfor gaskets, seals, brushes or the like. When the main panel 41 ispositioned within the side retention flanges 84 of the fixed bracket 80,the seals 55,155 extend from the edges of the main panel 41 and are in aposition to abut an adjacent structure, thereby forming a sealtherewith. As shown therein, the upper end 98 of the seal 55 iscompressed into the V-shaped groove 56 by the retention flange 84, whilethe lower end 99 of the seal 55 remains uncompressed. It will beappreciated, however, that when the header panel assembly 150 isproperly installed in place next to another header panel assembly 150, aside seal assembly or another structure, the lower end 99 of the seal 55will usually be compressed as well, thereby sealing the header panelassembly 150 against the respective structure.

In FIG. 12, a main panel 45 of a header panel assembly 250 includesflanges 47,147 at the sides and bottom thereof that extend away from themain panel 45 at an angle. Each angled flange 47,147 defines an outeredge to which a respective brush seal 71,171 is attached. Each brushseal 71,171 includes a cradle portion 75 that attaches along the outeredge of the angled flanges 47,147 and a brush portion 77 that is adaptedto be snap-fit into the cradle portion 75. Bristles 79 of the brushportion 77 extend away from the main panel 45 and are in a position toabut an adjacent structure, thereby forming a seal therewith. As shownin FIG. 12, bristles 79 at the upper end 198 of the brush seal 71 aredeflected by the retention flange 84 while bristles 79 at the lower end199 of the brush seal 71 remain undeflected. It will be appreciated,however, that when the header panel assembly 250 is properly installedin place next to another header panel assembly, a side seal assembly oranother structure, the lower end 199 of the brush seal 71 will usuallybe deflected as well, thereby sealing the header panel assembly 250against the respective structure.

In FIG. 13, the main panel 45 of a header panel assembly 350 includesflanges 47,147 at the sides and bottom thereof that extend away from themain panel 45 at an angle. Each angled flange 47,147 defines an outeredge to which a respective deflectable blade seal 91,191 is attached.Each blade seal 91,191 includes an attachment portion 93 that is adaptedto fittingly accommodate an outer edge of a corresponding angled flange47,147. Each blade seal 91,191 further includes a blade portion 95 thatextends away from the main panel 45 and is in a position to abut anadjacent structure so as to form a seal therewith. As shown in FIG. 13,the blade portion 95 is deflected by, and forms a seal against, theretention flange 84. It will also be appreciated that when the headerpanel assembly 350 is properly installed in place next to another headerpanel assembly, a side seal assembly or another structure, any portionof the blade seal 91 that extends below the retention flange 84 wouldlikewise be deflected by an adjacent structure and, thus, capable ofsealing the header panel assembly 350 against the respective structure.

In at least some commercial embodiments, header panel assemblies 50 ofdifferent vertical dimensions are provided to accommodate enclosures 14and frame structures 12 or other structures of different sizes. Forexample, FIGS. 14A-14C are isometric views of header panel assembliessimilar to that of FIG. 3 but having different vertical dimensions. Itwill also be appreciated that different widths may likewise be provided.

Air sealing along the sides of electronic equipment enclosures 14 at theends of the row of enclosures 14 may be facilitated by the side sealassemblies 100. FIG. 15 is an isometric view of one of the side sealassemblies 100 of FIG. 1. As shown therein, each side seal assembly 100includes a vertical support bracket 102 and a seal 105. The verticalsupport bracket 102 may be attached to a vertical post 16 of the framestructure 12, or other structure, via a plurality of horizontal slots108. The slots facilitate lateral adjustment along the width of thevertical post 16.

FIG. 16 is a fragmentary top cross-sectional view of the left end of thehot/cold aisle containment system 10 of FIG. 1, taken along line 16-16,illustrating the interface between a header panel assembly 50 and a sideseal assembly 100. As shown therein, the vertical support bracket 102includes a V-shaped flange 104, similar in cross-section to the V-shapedflanges 54,154 of the main header panel 52, which defines a groove 106of corresponding shape. The groove 106 is adapted to receive a seal 105which is also of similar cross-section and material to the seals 55,155of the header panel assembly 50. As shown therein, the seal 105 of theside seal assembly 100 is compressed by and against the side seal 55 ofthe adjacent header panel assembly 50 and also by the body of theelectronic equipment enclosure 14 below. In combination with thevertical support bracket 102, the seal 105 of the side seal assembly 100thus provides top-to-bottom sealing between both the leftmost enclosure14 of FIG. 1 and the leftmost header panel assembly 50. It will beappreciated that the vertical support bracket 102 may be adjustedlaterally, as described previously, to customize the spacing between theV-shaped flange 104 and the enclosure 14/header panel assembly 50. Whilea compressible seal is depicted in FIGS. 15 and 16, it is contemplatedthat a wide variety of different seals, including brush seals anddeflectable blade seals, may be used in connection with the side sealassembly 100. Furthermore, while the flanges 54,154 are shown asV-shaped, it is contemplated that the flanges 54,154 may have any of awide variety of different shapes and configurations, including generallyperpendicular flanges and angled flanges.

When installed next to an enclosure 14 and the header panel assembly 50above it, the side seal assembly 100 thus blocks the space between theenclosure 14 and the vertical post 16 and prevents recirculation ofheated air from the rear of the enclosure 14 around the side thereofwhere it could mingle with the cooling air being provided to theenclosure front.

FIG. 17 is an isometric view of a hot/cold aisle containment system 110in use with a row of electronic equipment enclosures 14 in accordancewith another preferred embodiment of the present invention. Inparticular, the containment system 110 of FIG. 17 includes a larger andmore comprehensive frame structure 112 adapted to receive and supportvarious panels and other structures to more fully enclose a hot aislebehind the enclosures 14. This frame structure 112, which includesadditional vertical posts 16 and horizontal beams 17,18 as well as aplurality of horizontal joists 22. Frame structures 112 suitable for usewith header panel assemblies 50 in accordance with one or more preferredembodiments of the present invention are described in commonly-assignedU.S. provisional patent application 61/411,359, entitled, “ADJUSTABLEWALL ASSEMBLY FOR HOT/COLD AISLE CONTAINMENT SYSTEM,” a copy of which isattached as Appendix A, which is expressly incorporated by referenceherein in its entirety.

One example of an assembly of panels to form a wall is shown in FIG. 18,which is an isometric view of a hot/cold aisle containment system 210 inuse with an electronic equipment enclosure 14 and an adjustable wallassembly 30 in accordance with still another preferred embodiment of thepresent invention. The enclosure 14 is installed at one end of the framestructure 112 and the adjustable wall assembly 30 is temporarilypositioned away from the enclosure 14 but can be moved toward theenclosure 14 to seal off the front end of the enclosure and the spacebehind it. Adjustable wall assemblies suitable for use with the framestructure 112 and header panel assemblies 50 in accordance with one ormore preferred embodiments of the present invention are described in theaforementioned '359 patent application, attached as Appendix A.

FIG. 19 is an isometric view of an overhanging beam 35 for use in ahot/cold aisle containment system, shown with a pair of adjustableheader panels 51 attached thereto. FIG. 20 is a fragmentary top view ofadjacent edges of the pair of adjustable header panels 51 of FIG. 19. Anoverhanging beam 35 may be mounted horizontally in a containment systemhaving a row of enclosures to provide another sealing option. As shownin FIG. 19, the overhanging beam 35 accommodates one or more headerpanels 51, each of which includes one or more adjustment slots 101. Theheader panels 51 are mounted directly to the overhanging beam 35 viaclamps 194, each extending through a respective adjustment slot 101 ofthe header panel 51 and into a respective clamp aperture (notillustrated) of the overhanging beam 35. The clamps 194 permit theheader panel 51 to be adjusted vertically relative to the overhangingbeam 35. By loosening the clamps 194 of a selected one of the headerpanels 51, the header panel 35 has infinite adjustability (within thedimensional range allowed by the adjustment slots 101). Tightening theclamps 194 fixes the header panel 35 into any desired position.

Each header panel 51 is generally flat with generally perpendicularflanges 53,153 along the sides and bottom thereof. Each perpendicularflange 53,153 defines an outer edge to accommodate and retain arespective seal 55,155. Each seal 55,155 includes a mounting portion 57adapted to attach to the edge of the perpendicular flange 53,153. Bosses(not illustrated) may be provided to assist in such attachment. Eachseal 55,155 further includes a body portion 58 comprised of acompressible material of any type conventionally utilized for gaskets,seals, brushes or the like. While a compressible seal is depicted inFIGS. 19 and 20, it is contemplated that a wide variety of differentseals, including brush seals and deflectable blade seals, may be used inconnection with the header panels 51. Furthermore, while the flanges53,153 are shown as generally perpendicular, it is contemplated that theflanges 53,153 may have any of a wide variety of different shapes andconfigurations, including V-shaped flanges and angled flanges. The seals55,155 extend from the edges of the header panel 51 and are in aposition to abut an adjacent structure so as to form a seal therewith.As shown in FIG. 20, the seals 55 of adjacent header panels 51 abut oneanother, thereby compressing the body portions 58 of each seal 55 andsealing off the boundary between adjacent header panels 51.

When installed above an enclosure 14 in a containment system andadjusted into position against the enclosure 14, the header panel 51 caneffectively block the space above the enclosure 14 and preventrecirculation of heated air from the rear of the enclosure 14 over thetop thereof where it could mingle with the cooling air being provided tothe enclosure front. With multiple header panels 51 installed, theheader panels 51 not only establish a seal with one another but may alsobe selectively adjusted to different heights, as depicted in FIG. 19, soas to accommodate varying heights among the enclosures installed in thecontainment system. The infinite adjustability (within the dimensionalrange) ensures that air gaps may be substantially entirely eliminated,and differences in enclosure heights managed effectively. Furthermore,by mounting the header panels 51 directly to the overhanging beam 35,the need for a separate telescoping panel to accompany the header panel51 may be avoided.

Based on the foregoing information, it will be readily understood bythose persons skilled in the art that the present invention issusceptible of broad utility and application. Many embodiments andadaptations of the present invention other than those specificallydescribed herein, as well as many variations, modifications, andequivalent arrangements, will be apparent from or reasonably suggestedby the present invention and the foregoing descriptions thereof, withoutdeparting from the substance or scope of the present invention.

Accordingly, while the present invention has been described herein indetail in relation to one or more preferred embodiments, it is to beunderstood that this disclosure is only illustrative and exemplary ofthe present invention and is made merely for the purpose of providing afull and enabling disclosure of the invention. The foregoing disclosureis not intended to be construed to limit the present invention orotherwise exclude any such other embodiments, adaptations, variations,modifications or equivalent arrangements; the present invention beinglimited only by the claims appended hereto and the equivalents thereof.

1. A hot/cold aisle containment system, comprising: (a) a framestructure adapted to be at least partially covered by one or more panelsto define an interior space, the frame structure including a verticalmember and a horizontal member; (b) at least one electronic equipmentenclosure installed at least partially within the frame structure; and(c) a header panel assembly installed between a top of the at least oneelectronic equipment enclosure and the horizontal member of the framestructure to prevent circulation of air above the enclosure, the headerpanel assembly including a main panel and at least one seal.
 2. Thehot/cold aisle containment system of claim 1, wherein the at least oneseal is disposed along the lower edge of the main panel and adapted tobe held in place between the bottom of the main panel and a top surfaceof the at least one electronic equipment enclosure.
 3. The hot/coldaisle containment system of claim 1, wherein the at least one seal isdisposed along a side edge of the main panel and adapted to be held inplace between the side of the main panel and an adjacent structure. 4.The hot/cold aisle containment system of claim 1, wherein the headerpanel assembly further includes a fixed bracket adapted to be supportedby the horizontal member of the frame structure, and wherein the mainpanel is adapted to be adjustably coupled to the fixed bracket.
 5. Thehot/cold aisle containment system of claim 4, wherein the header panelassembly further includes at least one clamp for retaining a portion ofthe main panel against a portion of the fixed bracket.
 6. The hot/coldaisle containment system of claim 1, wherein a V-shaped flange isdisposed at an edge of the main panel, and wherein the at least one sealis disposed at least partially in a groove defined by the V-shapedflange.
 7. The hot/cold aisle containment system of claim 1, wherein agenerally perpendicular flange is disposed at an edge of the main panel,and wherein the at least one seal is disposed along an outer edge of thegenerally perpendicular flange.
 8. The hot/cold aisle containment systemof claim 1, wherein an angled flange is disposed at an edge of the mainpanel, and wherein the at least one seal is disposed along an outer edgeof the angled flange.
 9. The hot/cold aisle containment system of claim1, wherein the at least one seal is compressible.
 10. The hot/cold aislecontainment system of claim 1, wherein the at least one seal is a brushseal.
 11. The hot/cold aisle containment system of claim 1, wherein theat least one seal is a deflectable blade seal.
 12. The hot/cold aislecontainment system of claim 1, further comprising a side seal assemblyinstalled between a side of the at least one electronic equipmentenclosure and the vertical member of the frame structure to preventcirculation of air around the enclosure.
 13. The hot/cold aislecontainment system of claim 12, wherein the side seal assembly includesa vertical support bracket and at least one seal, the vertical supportbracket being adapted to support the side seal assembly from thevertical member of the frame structure.
 14. The hot/cold aislecontainment system of claim 13, wherein the vertical support bracketincludes one or more horizontal slots to facilitate lateral adjustmentthereof.
 15. The hot/cold aisle containment system of claim 13, whereina V-shaped flange is disposed along an edge of the vertical supportbracket, and wherein the at least one seal is disposed at leastpartially in a groove defined by the V-shaped flange.
 16. The hot/coldaisle containment system of claim 12, wherein the side seal assembly isadapted to extend from the top to the bottom of the frame structure. 17.The hot/cold aisle containment system of claim 1, wherein the main panelis mounted to the horizontal member and adapted to be adjustable in avertical direction relative to the horizontal member.
 18. A hot/coldaisle containment system, comprising: (a) a frame structure adapted tobe at least partially covered by one or more panels to define aninterior space, the frame structure including a vertical member; (b) atleast one electronic equipment enclosure installed at least partiallywithin the frame structure; and (c) a side seal assembly installedbetween a side of the at least one electronic equipment enclosure andthe vertical member of the frame structure to prevent circulation of airaround the enclosure.
 19. The hot/cold aisle containment system of claim18, wherein the side seal assembly includes a vertical support bracketand at least one seal, the vertical support bracket being adapted tosupport the side seal assembly from the vertical member of the framestructure.
 20. The hot/cold aisle containment system of claim 19,wherein the vertical support bracket includes one or more horizontalslots to facilitate lateral adjustment thereof.
 21. The hot/cold aislecontainment system of claim 19, wherein a V-shaped flange is disposedalong an edge of the vertical support bracket, and wherein the at leastone seal is disposed at least partially in a groove defined by theV-shaped flange. 22.-54. (canceled)